Redwood Global Ltd, Unit 86, Livingstone Road, Walworth Business Park, Andover,

Hampshire. SP10 5NS. United Kingdom

Woodchipper USER MANUAL

ENGLISH

3/12/2015 Revision 13

P a g e | 1

Table of Contents Introduction ............................................................................................................................................ 3

Purpose of machine ............................................................................................................................. 4

Exterior component identification ....................................................................................................... 5

Safety ..................................................................................................................................................... 7

Safe working ..................................................................................................................................... 7

Machine lifting ................................................................................................................................... 8

DOs and DON’Ts ............................................................................................................................. 9

Noise test information ........................................................................................................................ 10

Machine operation .............................................................................................................................. 11

Machine control panel, start/stop & operating settings ............................................................ 12

Ignition switch ................................................................................................................................. 12

Feed speed adjustment ................................................................................................................. 14

Feed jam & blockages ....................................................................................................................... 15

Transportation ..................................................................................................................................... 16

Attaching to the vehicle tow hitch ................................................................................................ 17

Unhitching the machine ................................................................................................................. 17

Routine maintenance ......................................................................................................................... 18

Debris screen .................................................................................................................................. 19

Engine maintenance ...................................................................................................................... 19

Fastener tightening torques .......................................................................................................... 19

Service schedule ............................................................................................................................ 20

Covers: engine, chipping chamber, side panels ........................................................................ 22

Engine bay ...................................................................................................................................... 23

Blade sharpening ........................................................................................................................... 25

Hydraulic oil filter ............................................................................................................................ 26

Drive belt tension ............................................................................................................................ 28

Battery .................................................................................................................................................. 29

Battery safety information ............................................................................................................. 29

Storage and transport .................................................................................................................... 29

Initial operation ............................................................................................................................... 29

Battery removal & maintenance ................................................................................................... 29

Charging .......................................................................................................................................... 30

Jump starting................................................................................................................................... 30

Taking battery out of service ........................................................................................................ 31

Parts lists ............................................................................................................................................. 32

P a g e | 2

Hopper tray touch sensor 12-A-020 ............................................................................................ 32

Chipping chamber assembly 12-A-005 ....................................................................................... 33

Chipping chamber assembly 12-A-005. Bottom feed. ............................................................. 33

Chipping chamber assembly 12-A-005. Bottom feed & anvil. ................................................ 35

Chipping chamber assembly 12-A-005. Drive .......................................................................... 36

Chipping chamber assembly 12-A-005. Flywheel drive. ......................................................... 37

Chipping chamber assembly 12-A-005. Bottom feed roller cover. ........................................ 38

Chute assembly 12-A-007 ............................................................................................................ 39

Top feed roller assembly 12-A-008 ............................................................................................. 40

Flywheel assembly 12-A-010 ....................................................................................................... 41

Flywheel belt tensioner assembly 12-A-012 .............................................................................. 42

Fuel tank assembly 12-A-026 ....................................................................................................... 43

Hydraulic pump assembly 12-A-022 ........................................................................................... 44

Light board assembly 12-A-024 ................................................................................................... 45

Running gear – hitch & axle ............................................................................................................. 46

Hydraulics circuit diagram ................................................................................................................. 46

Electrical circuit diagram – Mechanical & touch sensor hopper ................................................. 47

Decals .................................................................................................................................................. 48

Manufacturer’s Statutory Plate ......................................................................................................... 49

Warranty .............................................................................................................................................. 50

CE Certificate ...................................................................................................................................... 51

P a g e | 3

Introduction Thank you for becoming the owner of this Redwood Global Ltd, Forst ST6

woodchipping machine. By observing the contents of this manual, we hope the

machine gives safe and productive service. This user manual is intended for the

owner/operator to safely and effectively operate this machine and carry out routine

maintenance between services. This is not a comprehensive service manual. See

Service Schedule for routine maintenance and when to take the machine to a service

specialist. For engine maintenance, please refer to the engine manual supplied with

this machine.

This machine has been through a pre-delivery inspection before leaving the factory

and is ready to use.

Before use and as a minimum, the safety and machine operation

sections covered on pages 4 to 13 must be read and understood.

Failure to do so could result in serious injury or loss of life to the

operator and others nearby. Also, damage to property and this machine may

occur. Please observe and obey all warning signs (decals) located on the machine.

Their meaning is covered in this manual under decals.

All personnel working with this machine must be adequately trained in its use and

most importantly, follow the advice on safe working practices.

Redwood Global Ltd endeavour to continuously develop and improve its products.

They reserve the right to make changes at any time, without notice or incurring any

obligation.

Continuous improvement will affect machine design and production so there may be

minor discrepancies between the actual product and this manual.

This manual must remain with the machine for reference by operators and includes

hiring or if the machine is resold.

P a g e | 4

Purpose of machine The Forst ST6 is designed to reduce wood material up to 150mm diameter to

woodchip. This machine is capable of processing up to 5 tonnes of wood per hour.

En

gin

e s

ize

K

ub

ota

4 c

yl d

iese

l R

olle

r fe

ed

T

win

se

rie

s h

yd

rau

lic m

oto

rs

Ma

xim

um

po

we

r 2

6.1

kW

(35

hp

) M

axim

um

ma

teria

l d

iam

ete

r 1

50m

m

Coo

ling m

eth

od

W

ate

r co

ole

d

Fu

el ca

pa

city

30

litre

s

Overa

ll w

eig

ht

95

5kg

Hydra

ulic

oil

ca

pa

city

20

litre

s

Sta

rtin

g m

eth

od

E

lectr

ic

Ma

teria

l p

roce

ssin

g c

ap

acity

5 T

onn

es/H

r

F

ue

l ty

pe

Die

se

l

P a g e | 5

Exterior component identification

Figure 1

1 TRIP BAR

2 CONTROL VALVE FEED SPEED ADJUSTMENT

3 HOPPER TRAY LATCH

4 HOPPER

5 CHIPPING CHAMBER COVER

6 CHUTE HOOD

7 CHUTE

8 MACHINE LIFTING EYE

9 ENGINE COVER

10 MANUFACTURER'S STATUTORY PLATE

11 SERIAL NUMBER

12 JOCKEY WHEEL HANDLE

13 VEHICLE CONNECTION LEAD

14 TOW HEAD

15 MACHINE LIGHT BOARD SOCKET

16 ENGINE COVER LATCH

17 CHIPPING CHAMBER

18 THROTTLE

19 GREASE POINT

20 IGNITION SWITCH

21 FUEL TANK

22 LIGHT BOARD

23 CONTROL PANEL

24 FEED START/STOP TOUCH SENSORS

25 HOPPER TRAY

P a g e | 6

Figure 2 1 SPARE WHEEL

2 CHUTE HANDLE

3 CHUTE HOOD LOCK HANDLE

4 CHUTE ROTATION LOCK HANDLE

5 SAFETY CURTAIN

6 REMOVEABLE NUMBER PLATE HOLDER

7 BATTERY

P a g e | 7

Safety

Safe working

Before using this machine, make sure that you are trained and fluent in its operation.

Know the location of and how to use all the safety features. Know how to control the

feed and stop the machine in an emergency. Be familiar with the hazards and safe

working practices to prevent injury and damage to property and machine. Also be

aware of the legal restrictions for personnel and towing with vehicles.

1. The minimum age for service personnel is 18 years. Personnel aged 16 can

use the machine for training under supervision by a suitably trained person of

18 years or over.

2. Operators and personnel working with this machine must not be under the

influence of alcohol, drugs or medication that would impair judgement,

concentration or reaction times. Excessive tiredness is also a risk.

3. In use, woodchip and debris are ejected with considerable force from the

chute and can travel up to 10m. Make sure the chute directs woodchip to a

safe location so that no one can be harmed or property damaged. Do not

allow discharge to be directed onto roads or public rights of way.

4. Maintain a 10m exclusion zone around the machine and clearly mark if in a

public area. Keep this area free of material build up.

5. Make sure the machine is on even, level and stable ground and cannot move

or topple when in use. Use wheel chocks if necessary.

6. Keep children and animals well away from the working area.

7. The machine operator must wear protective equipment:

a. Chainsaw safety helmet with mesh visor.

b. Correctly rated ear defenders.

c. Work gloves with elasticated wrist bands.

d. Steel toe cap boots.

e. Close fitting heavy duty non-snag clothing.

f. Protect breathing with a face mask if appropriate. Some plant material

can give off harmful dust and poisonous vapours. This may cause

respiratory problems or serious poisoning. Check the material to be

processed before starting.

g. DO NOT wear rings, bracelets, watches, jewellery or anything that

could be caught on the material being fed and draw you into the

machine.

8. All personnel operating or feeding material into the machine must wear heavy

duty non-snag clothing to help prevent being caught on material and drawn

into the machine. The feed mechanism of this machine uses high powered

hydraulic motors to drive sharp toothed rollers that feed material into the

cutting blades. DO NOT take risks with it. NEVER ASSIST ANY MATERIAL

INTO THE FEED ROLLERS WITH HANDS OR FEET. Use a push stick or

further long material if necessary.

9. Never climb onto the hopper area while the machine is in operation.

10. Material can be forcibly ejected from the hopper towards the operator. Ensure

full head and face protection is worn.

P a g e | 8

11. Very twisted material should be trimmed into manageable pieces. Failure to

do this can result in material extending outside the hopper, moving

aggressively side-to-side creating a hazard to the operator.

12. Do not try to force material over 150mm in diameter into the machine.

13. Carefully site the machine so operators can work furthest from any local

danger. For example, on a road side, place machine so operators work on

the verge and not in the road exposed to traffic.

Machine lifting

The lifting eye is designed for securely holding the machine’s weight only. Do not

use hoist hook directly on the lifting eye. Use a correctly rated safety shackle.

Inspect lifting eye before each use and do not use if damaged.

Figure 3

P a g e | 9

DOs and DON’Ts

DO stop the machine before making

any adjustments, refuelling or

cleaning.

DO make sure the machine has

stopped rotating and remove the

ignition key before any maintenance or

the machine is left unattended.

DO ensure that the machine is level,

well supported and cannot move

during use.

DO run the machine at full throttle.

DO conduct regular machine checks

for visual fluid leaks.

DO take regular breaks. Wearing

protective equipment can be hot and

tiring leading to a lack of

concentration, increasing the risk of

having an accident.

DO keep hands, feet and clothing out

of feed area, chute and moving parts.

DO NOT use machine in poor visibility

or insufficient light to see clearly.

DO NOT use or attempt to start the

machine without the discharge chute

or guards correctly and securely fitted.

DO NOT stand in front of the chute.

DO NOT allow the following to enter the machine as damage is likely:

BRICKS METAL

STRING GLASS

CLOTH RUBBER

PLASTIC ROOTS

STONES BEDDING PLANTS

DO NOT smoke when refuelling.

Diesel fuel is highly flammable and

explosive in certain conditions.

DO NOT let anyone who has not

received instruction, operate the

machine.

DO NOT climb on the machine at any

time except for a tracked machine

ride-on plate where fitted.

DO NOT handle material partially

engaged in the machine while in

operation.

DO NOT touch any exposed wiring

while the machine is running.

P a g e | 10

Noise test information Machine Forst ST6

Notes Tested chipping 50 x 50mm sawn pine 4.2m in length.

Noise levels above 85dB (A) will be experienced at the working position and within a

4 metre radius. Operators and personnel within a 4 metre radius must wear

appropriate ear protection at all times while machine is in operation to prevent the

risk of hearing damage.

A-weighted emission sound pressure (beside operator’s ear) LpA = 111.7dB(A).

Peak C-weighted instantaneous sound pressure (beside operator’s ear) LCpeak =

136.7dB(C). Results at 10 metre radius are calculated.

Guaranteed sound power: 122dB(A)

As required by Machinery Directive 2006/42/EC “Noise Emission in the environment

by equipment for use outdoors.”

P a g e | 11

Machine operation

MACHINE USE

TOUCH SENSOR HOPPER

STAGE

1 Fold down hopper tray

Start engine.

Turn ignition key to pre-heat

2Wait for display to indicate"Start

Engine"

Turn key to start engine and let go once

engine has fired

3Allow engine to run for 30 seconds then

open throttle to full

4For forward feed, touch green button

twice

5 Feed material

6 To stop, touch red button or push trip bar

7To reverse feed, touch green button

once

8 To stop machine

9 Touch red button or push trip bar

10 Close throttle to minimum

11 Switch off ignition and remove key

12 Before transporting machine

14 Sweep out debris from hopper

15Close hopper tray by lifting fully up

against stops and engage latch

P a g e | 12

Machine control panel, start/stop & operating settings

This machine is fitted with an engine PLC (Programmable Logic Controller) system

that manages the engine, feed and all safety features. The control panel is located

on the right side panel (see Figure 1). Feed and engine speed are controlled with a

“No Stress” function ensuring that cutting conditions are kept within optimum limits.

This maximises throughput while minimising jams and blockages. There will be

times when material is being cut and the feed will momentarily stop until engine

speed increases. At this point, the feed will start without warning. Service warnings

shown below will be displayed at certain intervals. The engine will not start until OK

is pressed.

First 20 Hour Warning: "Change Hydraulic Oil Filter" Every 20 Hour Warning: "Blade and Machine check required see manual" 50 Hour Service Warning: "1st Full Service recommended" Every 200 Hour Service Warning: "Full Service recommended"

Using the control panel:

Ignition switch

Figure 4

Turn ignition key clockwise to first position, then to pre-heat (see Figure 4), start

display will show, enables pre-heat automatically showing start display + pre-heat.

OR with Pre-heat

Turn ignition key fully clockwise to crank engine. Display will automatically go to P1

1 KEY ROTATION IN SWITCH TO START

2 IGNITION SWITCH POSITIONS & FUNCTION

3 OFF

4 IGNITION

5 PRE-HEAT

6 SWITCH SPRING BIASED TO PRE-HEAT WHEN RELEASED

7 START

8 KEY ROTATION IN SWITCH TO STOP

P a g e | 13

If engine fails to start, turn key to off position and start process again. P1 shows

Working Hours and charging indicator text at the screen bottom centre.

P2 shows I/O tests. Tests all functions and safety controls.

Pin screen

P3 shows No-Stress Settings

Actual RPM

Upper Band - 1400 RPM

Mid Band – 1125 RPM

Lower Band – 925 RPM

Pin screen automatically displays if any setting changes are attempted.

P a g e | 14

P4 shows Pre-Heat Settings

Enable Pre-Heat – True

Pre-Heat Time – 10

Crank Time – 3

Feed speed adjustment

Figure 5

The feed speed can be adjusted to suit the material being chipped see Figure 5.

Turn dial to align number with pip. Set feed speed so that the No-Stress operates as

little as possible, this will give the highest throughput. When feeding Leylandii or

leafy material, set feed roller speed to 4.5.

To stop engine turn off with

ignition key by turning fully anti-

clockwise.

1 CONTROL VALVE FEED SPEED ADJUSTMENT. POSITION INDICATED BY PIP. 0 = MINIMUM 10 = MAXIMUM

P a g e | 15

Feed jam & blockages Be aware that whatever is fed into the machine has to come out of the chute.

Always monitor the state of chip flow out of the chute. If this stops, STOP FEEDING

MATERIAL IMMEDIATELY. Continuing to feed material will further compact a

blockage and make it more difficult to clear.

If the chipping chamber or chute become blocked:

1. Stop the engine and remove ignition key.

2. Remove chute and check that it is clear.

3. If the chipping chamber is blocked, open the engine cover, then chipping

chamber cover. DO NOT REACH INTO THE CHIPPING CHAMBER WITH

HANDS. Beware that the flywheel within the chipping chamber has two sharp

blades mounted on it and can move causing a serious injury risk. Wearing

protective gloves and using a piece of wood, carefully clean out the chipping

chamber.

If feed becomes jammed (see Figure 6):

1. Stop the engine and remove ignition key.

2. Open engine and chipping chamber covers.

3. Release feed roller spring tension on both sides by slackening off the eye bolt

nuts and remove if necessary.

4. Insert feed lift tool and lift top feed roller to fully open.

5. Insert M12 screw into side of feed chamber and screw completely in. Lower

top feed roller onto the screw to secure in the open position.

6. There should now be access to the feed chamber. Beware that this is the

machines cutting zone. The top and bottom feed rollers have sharp teeth and

the flywheel cutting blades are not far from them. DO NOT PUT HANDS

INTO THIS AREA. Wearing protective gloves and using a piece of wood,

carefully clear jammed material inside feed chamber.

7. When clear, lift top feed roller via lifting tool, remove top feed M12 securing

screw, lower top feed roller and remove lifting tool.

8. Re-assemble feed tensioner springs and replace covers.

P a g e | 16

Figure 6

Transportation

· When towing the machine the maximum legal speed limit is 60mph.

· On very rough and uneven road surfaces, reduce speed to protect the

machine from undue vibration.

· When off road, avoid objects that may collide with the machine underside.

· Avoid steep gradients when off road.

· Avoid excessively pot holed ground.

· Exercise caution when reversing the machine as the short wheel base will

react quickly to steering.

· Keep tyre pressures inflated to 2.8 Bar or 41 psi.

· Check wheel nuts are tightened to between 90Nm and 100Nm.

· Clear machine of loose woodchip material before departing.

· Ensure the chute is securely fixed at the inboard position before departing.

· Ensure that the hopper tray is closed in the up position and the locking latch is

fully engaged before departing.

1 REMOVE EYE BOLT NUT BOTH SIDES BEFORE LIFTING FEED ROLLER

2 INSERT TOP FEED ROLLER LIFTING TOOL INTO SLOT AND LIFT

3 INSERT M12 SCREW TO HOLD FEED IN OPEN POSITION

P a g e | 17

Attaching to the vehicle tow hitch

· Check that the vehicle ball hitch is well greased.

· Raise the machine hitch by turning the jockey wheel handle anticlockwise until

the hitch socket is above the vehicle hitch ball.

· Reverse the vehicle until the ball is directly below the machine hitch socket.

· Attach the breakaway cable/secondary coupling to a suitably strong point on

the vehicle, not the ball hitch.

· Ensure the barrel lock is retracted from the tow head.

· Grasp handle on tow head and push back catch with thumb.

· Wind the jockey wheel handle clockwise to lower the hitch socket onto the ball

hitch.

· Release tow head handle and continue to wind the jockey wheel handle

clockwise. The tow head should snap into place on the ball hitch. If it

doesn’t, repeat previous two steps.

· Wind jockey wheel up until fully retracted and the jockey wheel frame is

seated in its notch on the stem. The machine’s weight should be fully on the

vehicle.

· Release the jockey wheel clamp and slide the jockey wheel assembly fully up

then tighten clamp.

· Connect the vehicle trailer socket to the machine socket with the connection

lead. Check all machine lights and tow vehicle lights are working correctly.

· Insert the barrel lock for security.

· The machine is now properly attached to the tow vehicle.

Unhitching the machine

· Ensure the machine will not roll away after being disconnected from the tow

vehicle.

· Disconnect the trailer socket from the tow vehicle.

· Release the barrel lock.

· Release the breakaway cable/secondary coupling.

· Release the jockey wheel assembly clamp, fully lower the wheel and tighten

the clamp.

· Wind the jockey wheel handle anticlockwise until it starts to take the machine

weight.

· Grasp the tow head handle and release the catch with your thumb.

· Wind the jockey wheel handle anticlockwise until the tow head is clear of the

ball hitch.

· Drive the tow vehicle clear of the machine.

· Level the machine by winding the jockey wheel handle.

· The machine is now fully detached from the tow vehicle.

P a g e | 18

Routine maintenance The following must be checked at least on a daily basis during use (also see Service

schedule):

· Check engine oil. See Figure 11

· Check water level in radiator reservoir bottle. See Figure 11

· Check debris screen on front of radiator and remove any debris (see Figure

7).

· Check hydraulic oil level. When the machine is new, the oil level may drop

during initial use. Regularly check and top-up until level settles. If a top up is

required, thoroughly clean around filler cap before removing to help prevent

debris falling into oil tank, top up as required and replace filler cap. See

Figure 12

· Grease machine. Every 8 hours, one pump of grease to each of the four

nipples at the central grease point manifold located near the control panel.

See Figure 1.

· Check all fasteners are present and assembled to the correct torque.

· Check proximity sensors on engine cover, removable hopper and trip bar are

not damaged and working correctly. The trip bar sensor is the most

vulnerable and if severely damaged could result in the trip bar not working.

· Check drive belt tension and adjust as necessary. See Figure 12, Figure 13 &

Figure 17.

· Check pulleys and taper lock on flywheel shaft. See Figure 13.

· Check flywheel blades for damage and sharpness. Machine performance is

adversely affected if blades are blunt or damaged. Replace and sharpen

blades as required. Make sure that the blade seat is clean and free of

damage before reassembly. Shims are available to adjust for blade size

reduction after sharpening. Please refer to blade sharpening for size limits,

adjustment shims and setting. Ensure blade fasteners are correctly installed

and tightened to the appropriate torque. Check after 1 hours’ work then

weekly.

· Anvil and side anvil are replaceable and double sided. Make sure that the

anvil seat is clean and free of damage before reassembly.

· Exercise extreme care to avoid injury when removing and replacing blades

and anvils. The flywheel can turn creating crush and cutting points in and

around the chipping chamber.

· Check all hydraulic hoses and fittings after 5 hours’ work. Beware of hydraulic

oil leaks, they can cause serious injury while the engine is running and the

system is under pressure. A leak can easily inject high pressure oil deep into

flesh and blood stream requiring immediate medical attention. DO NOT

CHECK FOR LEAKS WHILE THE ENGINE IS RUNNING. Hoses to the feed

roller hydraulic motors are the most likely to become damaged as they are

P a g e | 19

constantly moving during use. If hoses are replaced, all seals must be

replaced at the same time.

· Check top and bottom feed motor bracket bolts weekly.

Debris screen

Figure 7

Engine maintenance

Please refer to the engine manual supplied with this machine for the following:

· Checking the engine oil.

· Changing the engine oil, oil filter and fuel filter.

Fastener tightening torques

Nominal

torque

Nm

Max/Min

torque

Nominal

torque

Nm

Max/Min

torque

Size

M6 10 9.5/10.4 14.5 14/15.3

M8 25 23.1/25.3 35 34/37.2

M10 49 46/51 72 68/75

M12 86 80/87 125 117/128

M12x1.5 wheel screws 95 90/100

M16 210 194/214 310 285/314

M20 410 392/431 610 558/615

M24 710 675/743 1050 961/1059

Class 8.8 Class 10.9

Tightening torques for class 8.8 and 10.9 fasteners

All machine fastener torques should be regularly checked to the above table. In

particular, those for the flywheel blades, flywheel bearings, axle assembly, hitch,

road wheels and engine mounts.

1 LOCATION SLOTS IN FRONT OF RADIATOR

2 DEBRIS SCREEN

P a g e | 20

Service schedule

Kubota engine Wood chipper

After first

5 Hrs

Every 8

Hrs

(Daily)

After first

10 Hrs

After first

20 Hrs

Every 20

Hrs

After first

50 Hrs

Every 50

Hrs

(weekly)

Every

100 Hrs

(2 weeks)

Every

200 Hrs

(monthly)

Every

250 Hrs

(monthly)

Tighten hydraulic fittings ●

Check fasteners ●

Check engine oil level &

top up if necessary ●

Visual check for fluid

leaks ●

Check drive belts ●

Grease via central point

on control panel ●

Change hydraulic filter

cartridge ●

Check brake adjustment

(wheeled only) ●

Check flywheel shaft

bearings ●

Check cutting blade &

anvil condition, change if

required●

Change oil & filter ●

Check fuel hoses and

clamp bands ●Check feed roller

tension springs &

replace if required●

Check wear mark on

towing hitch (wheeled

only)●

Clean air filter element ●

Clean fuel filter ●

Check battery electrolyte

level ●

Check fan belt tension ●

Re-sharpen feed rollers

as required ●

Check radiator hoses &

clamp bands ●

Replace oil filter

Check feed roller

bearings on motor side,

rotate 180 deg●

Check air intake hose ●

Check & recharge

battery ●

Service Schedule

P a g e | 21

Service schedule

Kubota engine Wood chipperEvery

400 Hrs

Every

500 Hrs

Every

800 Hrs

Every

1000 Hrs

Every

1500 Hrs

Every

2000 Hrs

Every

3000 Hrs

Every 12

months

Every 2

years

Every 5

years

Replace fuel filter

cartridge ●

Change feed roller

bearings on motor side ●

Clean out fuel tank ●

Clean radiator ●

Replace engine fan belt ●

Check & recharge

battery ●

Change hydraulic filter

cartridge ●

Check valve clearances ●

Change hydraulic oil ●

Check fuel injector

pressure ●

Check fuel injection

pump ●

Check fuel injection

timer ●

Get the machine

overhauled by a service

specialist●

Change air filter element ●

Check wiring for

damage & loose

connections●

Change radiator coolant ●Replace battery ●

Replace radiator hoses

& clamp bands ●

Replace fuel hoses &

clamp bands ●

Change air intake hose ●

Change hydraulic hoses ●

Service Schedule

P a g e | 22

Covers: engine, chipping chamber, side panels

COVER OPENING SEQUENCE, A then B

Figure 8

Figure 9 1 LEFT SIDE PANEL CAN BE REMOVED FOR ACCESS TO FEED ROLLER TENSION SPRING ANCHORS. OPPOSITE SIDE PANEL CAN ALSO BE REMOVED

2 6x FASTENERS

3 HYDRAULIC OIL FILTER HOUSING

1 ENGINE COVER LATCH

2 2x M12 SCREWS SECURE COVER IN CLOSED POSITION

P a g e | 23

Figure 10

Engine bay

Figure 11

1 OIL DIP STICK

2 ENGINE OIL FILLER CAP

3 RADIATOR FILLER CAP

4 DEBRIS SCREEN

5 RADIATOR RESERVOIR BOTTLE

6 AIR FILTER

7 CHIPPING CHAMBER COVER FIXING

8 ANVIL CLAMP BOLT

1 TOP FEED ROLLER M12 SECURING SCREW HOLE

2 CHIPPING CHAMBER COVER FIXING SCREWS

3 SIDE PANELS

4 TOP FEED ROLLER LIFTING TOOL SOCKET

P a g e | 24

Figure 12

Figure 13

1 HYDRAULIC OIL FILLER CAP

2 HYDRAULIC OIL LEVEL SIGHT GLASS

3 PUMP BELT TENSIONER SCREW

4 HYDRAULIC PUMP CLAMP SCREWS

5 HYDRAULIC PUMP

1 FLYWHEEL BELT TENSIONER IDLER PULLEY

2 FLYWHEEL TAPER LOCK RETAINER

3 FLYWHEEL DRIVE BELT TENSION ADJUSTMENT

4 FUEL FILTER

5 FLYWHEEL DRIVE BELT TENSION ADJUSTMENT

P a g e | 25

Blade sharpening

For optimum performance, blades need to be kept sharp. Minimum safe blade size

after sharpening is shown in Figure 14. After sharpening, the blade gap must be re-

set by using a blade shim as shown in

Figure 15. Shims are available in thicknesses of 0.5, 1, 1.5, 2 & 2.5mm as part

number 12-03-093. On no occasion must more than one shim be fitted under each

blade at any time. A gap of 0.5mm must be set from the inner blade tip to anvil after

sharpening by placing an appropriate shim under the blade (also see flywheel

assembly). The outer blade tip is automatically set due to the anvil being set at an

angle to the blade. With 0.5mm at the inner blade tip, the outer blade tip should be

3mm from the anvil as shown in

Figure 16.

The complete blade fastener set must be replaced every time blades are changed.

Blade sharpening limit 80mm to 60mm Figure 14

Figure 15

1 Flywheel

2 Flywheel blade

3 Blade shim

4 M16 10.9 hex nut

5 M16 x 45Lg 10.9 CSK hex socket screw

6 M16 serrated lock washer

P a g e | 26

Figure 16

Hydraulic oil filter

Use protective plastic gloves to keep oil off skin, dispose of oil and filter in an

environmentally responsible manner.

1 SIDE ANVIL

2 ANVIL

3 OUTSIDE BLADE GAP

4 FLYWHEEL BLADE

5 INSIDE BLADE GAP

Item Description Quantity

1 Complete filter 1

2 Filter element 1

3 Seal kits 1

3a O-ring for filter element 1

3b O-ring for housing 1

3c Anti-extrusion ring 1

3d Gasket 1

3e O-ring 1

3f Protection seal 1

4 Indicator plug 1

P a g e | 27

1. The filter housing is accessed via the left side panel (see covers Figure 9).

Thoroughly clean around filler housing before removing to help prevent debris

getting into oil.

2. Unscrew filter housing body, remove filter element and allow to drain for 15

minutes before disposal.

3. Screw on and tighten filter body with new seals and filter into filter housing.

Oils, Fluids and Lubricants

Engine Oil: HD SAE 15w40

Please consult your supplied Kubota engine operator’s manual for oil quantities relating to your engine type.

Hydraulic Oil: ISO VG 46.

It is advised that the oil is checked and topped up to the RED LINE on the sight

glass, when the machine is cold and on a level surface.

Anti-Freeze: Mono-ethylene Glycol at a 50% mix ratio.

Please consult your supplied Kubota engine operator’s manual for coolant quantities relating to your engine type.

Grease: Lithium EP2 General Purpose

1 UNSCREW FILTER BODY TO REPLACE FILTER ELEMENT

P a g e | 28

Drive belt tension

Both Hydraulic pump and flywheel V belts must be checked for tension and

condition. If any belt shows signs of wear, surface damage, shredding, excessive

glazing, or have been stretched to their limit, they must be replaced. Multiple belt

drives must have all belts replaced at the same time. Belts that are too slack will

cause poor cutting performance, excessive belt and pulley wear.

All drive belts are located under the engine cover as shown in Figure 12 and Figure

13 and tension checked at arrows shown in Figure 17. Check and set tension as

follows:

1. Slacken clamp screw(s) or nut.

2. Hydraulic pump adjuster screw requires its lock nut to be slackened.

3. Turn adjuster nut or screw to tension belt until 4.5Kg force at the belt longest

centre span deflects by 6mm (see Figure 17). Can be approximated by firmly

gripping belt between finger and thumb and twisting. The belt should not be

able to be rotated more than 90°.

4. Tighten all lock nuts, nuts and clamp screws.

5. Run machine and test.

6. Check belt tension.

Figure 17

1 FLYWHEEL DRIVE BELTS. CHECK TENSION HERE

2 HYDRAULIC PUMP DRIVE BELT. CHECK TENSION HERE

3 HYDRAULIC OIL LEVEL IN SIGHT GLASS

P a g e | 29

Battery

Battery safety information

1. Battery acid is highly corrosive. For safety reasons, wear eye protection when

handling a battery. Do not tilt battery as acid could escape from vents. 2. Keep children away from acid and batteries. 3. Battery emits highly explosive hydrogen gas when charged. Do not allow

fires, sparks, naked flames or smoking near the battery. Also avoid

electrostatic discharges and electrical sparks when dealing with cables and

electrical equipment. 4. First aid. If acid is splashed into eyes, immediately rinse with clean water for

several minutes and consult a doctor without delay. If acid is swallowed,

consult a doctor immediately. Neutralise acid splashes on the skin and

clothes immediately with acid neutraliser (a solution of water and soda/baking

soda) or soap suds, and rinse with plenty of clean water. 5. Battery case can become brittle. To help avoid this, do not store batteries in

direct sunlight. Discharged batteries could freeze so store in a frost-free area. 6. Dispose of old batteries at an authorised collection point. Never dispose of in

household waste.

Storage and transport

1. As batteries are acid filled, always store and transport them upright and

prevent from tilting to avoid acid escape.

2. Store in a cool, dry, frost free place.

3. Do not remove the protective positive terminal cap.

4. Run a First-in First-Out (FIFO) warehouse management system.

Initial operation

1. Batteries are filled with acid at a density of 1.28g/ml at 15°C during

manufacture and are ready for use.

2. Recharge in case of insufficient starting power (see charging).

Battery removal & maintenance

To remove and replace battery:

1. Switch off engine and all electrical equipment.

2. To gain access to the battery, remove left side panel as shown in Figure 9 &

Figure 18.

3. Avoid short circuiting the battery terminals and from positive to any metal

machine part. Loose metal parts and tools commonly cause this.

4. Remove excessive debris from around the battery.

5. First remove negative lead at the battery, then the positive. Battery terminals

are the take-off type and fastened with an M6 screw in to a ferrule on the

cable end.

P a g e | 30

6. Slacken the M8 battery clamp screw.

7. Remove battery. Clean with a moist anti-static cloth to avoid electrostatic

discharge and explosion risk. Charge and check electrolyte level if

appropriate.

8. Clean out battery tray. Apply a thin film of petroleum jelly to terminals to

prevent corrosion.

9. Replacement is the reversal of removal. Ensure to replace/fit any vent pipes.

Leave at least one vent open otherwise there is an explosion risk. This also

applies to old batteries removed for disposal/recycling. Swap new battery

positive terminal protective cover to the old battery positive terminal to help

prevent short circuits and sparks.

Figure 18

Charging

1. Remove battery from machine, disconnect negative terminal first.

2. Ensure good ventilation.

3. Use suitable direct current mains chargers only.

4. Connect battery positive terminal to charger output positive. Connect the

negative terminal accordingly.

5. After connection, switch on charger. When charging is complete, switch off

charger then disconnect battery.

6. Charging current recommendation is 10% of the battery Ah power rating.

7. Use a charger with a constant charging voltage of 14.4V.

8. If the acid temperature rises above 38°C, stop charging.

9. The battery is fully charged when the charging voltage or acid specific gravity

has stopped rising for two hours.

Jump starting

1. Use a standardised jumper cable to DIN 72553 only and follow the

instructions.

1 TAKE-OFF BATTERY TERMINALS FASTENED WITH M6 SCREW

2 BATTERY

3 BATTERY CLAMP M8 SCREW

P a g e | 31

2. Only use batteries of the same voltage.

3. Switch off ignition on machine and support vehicle. The two must not touch

and all lights/equipment must be turned off.

4. Referring to Figure 19, connect in the sequence of 1 – 2 – 3 – 4 as shown and

as follows: Connect one end of the red jump lead to the machine battery

positive (+) terminal.

5. Connect the other end of the red jump lead to the support vehicle battery

positive (+) terminal.

6. Connect one end of the black jump lead to the support vehicle battery

negative (-) terminal.

7. Connect other end of the black jump lead to a machine metal part away from

the battery eg. onto the engine from under the chassis.

8. Make sure that the jump leads will not come into contact with moving parts.

9. Start the support vehicle engine and run at a medium idle speed for 15

seconds.

10. Start machine and run for 15 seconds.

11. Disconnect jump leads in the reverse order 4 – 3 – 2 – 1.

Figure 19

Taking battery out of service

1. Charge the battery and store in a cool but frost free place or on the vehicle

with the negative terminal disconnected.

2. Check the battery charge at regular intervals. Recharge if necessary.

A Support vehicle battery

B Machine battery

P a g e | 32

Parts lists

Hopper tray touch sensor 12-A-020

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Chipping chamber assembly 12-A-005

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Chipping chamber assembly 12-A-005. Bottom feed.

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Chipping chamber assembly 12-A-005. Bottom feed & anvil.

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Chipping chamber assembly 12-A-005. Drive

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Chipping chamber assembly 12-A-005. Flywheel drive.

Item No Part No Description Quantity

1 12-10-056 V belt 17 x 1975mm Ld 2

P a g e | 38

Chipping chamber assembly 12-A-005. Bottom feed roller cover.

TOP

Item No Part No Description Quantity

1 12-12-504 M10 x 20Lg 8.8 Hex Head screw 2

2 12-14-010 M10 Spring Washer DIN 128 2

3 12-14-009 M10 Washer ISO 7089 2

4 12-03-045 Feed roller cover 1

P a g e | 39

Chute assembly 12-A-007

Item No Part No Description Quantity

1 12-19-056 Chute clamp fab assy 2

2 12-20-001 Spring Pin Slotted 10 DIA x 30Lg ISO 8752 2

3 12-10-005 M16 T bar screw 2

4 12-19-051 Chute fab assy 1

5 12-11-007 Plain bearing 12 ID, 16 OD, 22 flange x 10 Lg 4

6 12-14-003 M12 Washer ISO 7089 6

7 12-13-003 M12 nyloc nut ISO 7040 3

8 12-01-043 Hood hinge stud 1

9 12-19-151 Chute hood fab assy 1

10 12-30-024 Forst small orange decal 2

11 12-15-020 M12 Elastomer washer OD 25-ID 12 x 5 THK 2

12 12-19-055 Chute handle - standard 1

13 12-10-004 M12 female steel handle 1

14 12-14-004 M12 Washer extra large OD 44 x 4 THK ISO 7094 2

P a g e | 40

Top feed roller assembly 12-A-008

P a g e | 41

Flywheel assembly 12-A-010

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12

-03

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3.1

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m

12

-03

-09

3.1

5

1.5

mm

12

-03

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3.2

0

2m

m

12

-03

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3.2

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2.5

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No

te:

Bla

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et

(Bo

lt,

Wa

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Pa

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99

-99

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9

P a g e | 42

Flywheel belt tensioner assembly 12-A-012

Item No Part No Description Quantity

1 12-12-1104 M16 x 110Lg 8.8 Hex Head bolt 1

2 12-14-019 M16 Spring washer DIN 128 1

3 12-14-005 M16 Washer ISO 7089 3

4 12-11-011 6304 2RS Deep groove ball bearing 52 OD, 20 ID, 15 wide 2

5 12-01-036 Flat idler pulley-2x 17 V belt 1

6 12-01-024 Flat idler pulley shaft-2x 17 V belt 1

7 12-13-005 M16 nyloc nut ISO 7040 1

8 12-19-062 Tensioner slide fab assy 1

P a g e | 43

Fuel tank assembly 12-A-026

Item No Part No Description Quantity

1 12-10-150 Fuel tank cap 1

1a 12-10-151 Lockable tank cap (optional) 1

2 12-10-152 Fuel tank filter 1

3 12-02-001 Fuel tank 35L moulded assy 1

4 12-10-154 Fuel tank 5mm connector 1

5 12-10-153 Fuel tank 5mm grommet 1

6 12-14-008 M12 Bonded washer (Dowty) 2

7 12-10-027 Banjo M12 1

8 12-10-026 Banjo bolt M12 1

P a g e | 44

Hydraulic pump assembly 12-A-022

P a g e | 45

Light board assembly 12-A-024

P a g e | 46

Running gear – hitch & axle Please refer to maintenance instruction manual supplied with the machine.

Hydraulics circuit diagram

1 Motor

2 Control valve

3 Test point

4 Filter

5 Pump

6 Oil tank

P a g e | 47

Electrical circuit diagram – Mechanical & touch sensor

hopper

P a g e | 48

Decals

Decal meaning:

1. Throttle movement relation to engine speed.

2. CE (Conformite Europeene or European Conformity) mark. Manufacturer’s

declaration that the product complies with the essential requirements of the

relevant European health, safety and environment protection legislation.

3. Ignition switch stop.

4. Hearing and eye protection of an appropriate specification to be worn.

5. Finger and toe amputation hazard.

6. Refer to user manual.

7. Allow machine to stop before touching.

8. Danger from flying objects.

9. Do not open or remove covers while engine is running.

10. Keep away from rotating machine parts.

11. Push to stop, trip bar operation.

These decals are placed on the machine where the hazard or information applies.

P a g e | 49

Manufacturer’s Statutory Plate

Information on the Manufacturer’s Statutory Plate in line order from top to bottom is

as follows:

1. Manufacturing company.

2. Vehicle type approval number and construction date.

3. 17 digit Vehicle Identification Number (VIN) construction.

4. Gross Vehicle Weight (GVW).

5. 0- Nose weight.

6. 1 - Axle mass.

7. 2 - Location.

P a g e | 50

Warranty

Warranty statement

1. Redwood Global Ltd guarantee all Forst equipment supplied by them against any defect in manufacture and assembly – this guarantee is for a period of 12 months commencing on the date of sale to the first end user.

2. The guarantee will not apply to a failure where normal use has exhausted the life of a component.

3. Engine units are covered independently by their respective manufacturer’s warranties.

4. Redwood Global Ltd’s liability under this guarantee is limited to repair at Redwood Global Ltd’s premises or at a selected Forst dealer.

5. No liability will be accepted for consequential lost or damage of any kind. 6. The Redwood Global Ltd guarantee is restricted to the first Redwood

Global Ltd user only and is not transferable except when authorized by Redwood Global Ltd.

7. The owner is responsible to make sure the machine is operated at all times in accordance with the user manual.

8. The Redwood Global Ltd guarantee will be invalidated if any of the following points apply:

· Failure to use genuine Forst parts

· Failure to perform routine servicing and maintenance

· Failed parts or assembly have been interfered with

· Machine has been modified without written approval from Redwood Global Ltd

· Machine has been used to performed tasks contrary to those stated in the Redwood Global Ltd User Manual

· Exclusions to the above warranty terms are – fair wear and tear on fuses and bulbs, tyres and brakes, lubrications and filters, blades and anvils, feed rollers and paintwork.

· Where an extended warranty has been given this will be stated on the original machine invoice and will be subject to further conditions as stated in our supplementary warranty terms

Warranty claims

To obtain warranty service please contact Redwood Global Ltd for the nearest

approved Forst Dealer. Your nearest dealer can be obtained from Redwood Global

Ltd at the address on the front of the User Manual. In the event of a failure Redwood

Global Ltd must be notified within 7 working days.

P a g e | 51

CE Certificate

CERTIFICATE & DECLARATION OF CONFORMITY FOR CE MARKING

Company contact details: Redwood Global Ltd,

Unit 86, Livingstone Road, Walworth Business Park, Andover, Hampshire. SP10 5NS. United Kingdom

Redwood Global Ltd declares that their:

Wood Chippers listed as the following models ST6 Towed & TR6 on Tracks ST8 Towed & TR8 on Tracks

are classified within the following EU Directives:

Machinery Directive 2006/42/EC Electromagnetic Compatibility Directive 2004/108/EC

and further conform with the following EU Harmonized Standards:

EN13525:2005 + A2:2009 EN 982:1996+A1:2008

EN ISO 12100:2010 EN ISO 14982:2009

Dated: …………………………

Position of signatory: Managing Partner Name of Signatory: Raymond Gardner

Signed below:

…….……………………………….

on behalf of Redwood Global Ltd